How to replace the vacuum brake booster on Chevrolet Aveo?

The first step to replace the vacuum Brake Booster includes unplugging its electrical connector from the reservoir. For manual car owners we disconnect the Clutch Hose clip from the master cylinder before plugging the Clutch Hose and master cylinder outlets. Detach the master cylinder nuts then move the master cylinder forward while protecting the brake lines and get rid of the older booster housing seal. Unfasten the vac outlet clip from the booster then remove the brake lamp switch and brake pedal spring. Unfasten the clip and Pushrod attachment point on the pedal bracket. After taking off the support bracket-to-dash panel nuts remove the booster with the bracket assembly from dash panel position. Take off the booster bracket nuts then pull out the rubber boot and retainer which must be followed by removal of the Pushrod and adjustment sleeve before getting to the hex nut. Check the Pushrod and adjustment sleeve components for damage and suitable alignment before installing them onto the booster along with the hex nut. Tighten the assembly to 16 nm (12 ft. Lbs.). Insert the Pushrod into the adjustment sleeve before mounting the retainer with care to reach a 10-inch distance between the booster and fork bin center. Fit the rubber boot on the booster then fasten the brackets before tightening booster-to-support nuts to 12 nm (9 ft. Lbs.). Secure the dash panel parts with two 24 nm (18 ft. Lbs.) torque settings on the booster and support bracket nuts. Attach the master cylinder to the booster unit by installing a new booster housing seal then tighten all master cylinder connecting nuts to 24 nm (18 ft. Lbs.). Attach the new vacuum hose to booster with proper dohc engine connection and tighten new hose clamps. Place the Pushrod pin into its original position on the brake pedal bracket before reconnecting its spring and clip. Besides, attach and tighten the brake lamp switch.

OEM Chevrolet Aveo Brake Booster

Brake Power Booster

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10 Brake Boosters found

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Chevrolet Aveo Brake Booster Part Number: 93744988
$169.86 MSRP: $318.99
You Save: $149.13 (47%)
Ships in 1-3 Business Days
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Product Specifications
- Other Name: Booster, Hydraulic Power Brake Booster; Booster
- Warranty: This genuine part is guaranteed by GM's factory warranty.
Fits the following Vehicles:
- 2009-2011 Chevrolet Aveo | LS, LT | 4 Cyl 1.6 L GAS
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Chevrolet Aveo Booster Assembly Part Number: 96652680
$202.08 MSRP: $379.51
You Save: $177.43 (47%)
Ships in 1-2 Business Days
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Product Specifications
- Other Name: Booster, Hydraulic Power Brake Booster; Brake Booster
- Replaced by: 95983232
- Warranty: This genuine part is guaranteed by GM's factory warranty.
Fits the following Vehicles:
- 2009-2010 Chevrolet Aveo | LS, LT | 4 Cyl 1.6 L GAS
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Chevrolet Aveo Booster Assembly Part Number: 95983238
$197.85 MSRP: $358.09
You Save: $160.24 (45%)
Ships in 1-2 Business Days
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Product Specifications
- Other Name: Booster, Hydraulic Power Brake Booster; Cylinder, Brake Master Cylinder; Brake Booster
- Replaces: 96652675
- Warranty: This genuine part is guaranteed by GM's factory warranty.
Fits the following Vehicles:
- 2009-2010 Chevrolet Aveo | LS, LT | 4 Cyl 1.6 L GAS
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Chevrolet Aveo Booster Assembly Part Number: 96534620
Product Specifications
- Other Name: Cylinder; Brake Booster
- Warranty: This genuine part is guaranteed by GM's factory warranty.
Fits the following Vehicles:
- 2004 Chevrolet Aveo | Base, LS | 4 Cyl 1.6 L GAS
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Chevrolet Aveo Booster Assembly Part Number: 96534593
Product Specifications
- Other Name: Cylinder, Brake Master Cylinder; Brake Booster
- Warranty: This genuine part is guaranteed by GM's factory warranty.
Fits the following Vehicles:
- 2004 Chevrolet Aveo | Base, LS | 4 Cyl 1.6 L GAS
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Chevrolet Aveo Booster Assembly Part Number: 96457292
Product Specifications
- Other Name: Cylinder; Brake Booster
- Warranty: This genuine part is guaranteed by GM's factory warranty.
Fits the following Vehicles:
- 2004 Chevrolet Aveo | Base, LS | 4 Cyl 1.6 L GAS
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Chevrolet Aveo Brake Booster Part Number: 96534598
Product Specifications
- Other Name: Booster, Hydraulic Power Brake Booster; Booster
- Warranty: This genuine part is guaranteed by GM's factory warranty.
Fits the following Vehicles:
- 2004-2008 Chevrolet Aveo | Base, LS, LT, Special Value | 4 Cyl 1.6 L GAS
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Chevrolet Aveo Booster Assembly Part Number: 96471214
Product Specifications
- Other Name: Cylinder, Brake Master Cylinder; Brake Booster
- Warranty: This genuine part is guaranteed by GM's factory warranty.
Fits the following Vehicles:
- 2005-2006 Chevrolet Aveo | LS, LT, Special Value | 4 Cyl 1.6 L GAS
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Chevrolet Aveo Booster Assembly Part Number: 95983234
Product Specifications
- Other Name: Booster, Hydraulic Power Brake Booster; Brake Booster
- Replaces: 96652678
- Warranty: This genuine part is guaranteed by GM's factory warranty.
Fits the following Vehicles:
- 2009-2011 Chevrolet Aveo | LS, LT | 4 Cyl 1.6 L GAS
View related parts
Chevrolet Aveo Booster Assembly Part Number: 95983229
Product Specifications
- Other Name: Booster, Hydraulic Power Brake Booster; Cylinder, Brake Master Cylinder; Brake Booster
- Replaces: 96652683
- Warranty: This genuine part is guaranteed by GM's factory warranty.
Fits the following Vehicles:
- 2009-2011 Chevrolet Aveo | LS, LT | 4 Cyl 1.6 L GAS

Chevrolet Aveo Brake Booster

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Chevrolet Aveo brake booster is a crucial part that strengthens the brake system of Chevrolet Aveo automobiles hence improving the safety while on the road. The Brake Booster has one of the best reputations when it comes to reliability and performance to the vehicle and in enhancing ease of the braking mechanism with less effort from the driver. Over the years, different Aveo models manufactured between 2002 and 2020 have gotten both Vacuum Operated and Hydraulic Brake boosters, each with some peculiarities. The vacuum Brake Booster is said to be durable for its reliable performance and the hydraulic Brake Booster offers constant help; therefore, it is used frequently in many cases. Its variety enables different options to be of certain size and single diaphragm ones to provide more assistance to the patient, while the dual ones work perfectly when there is little space available. The Chevrolet Aveo's trims include the 3/5 door hatchback and the 4 door sedan all of which when fitted with these Brake Boosters, experience an improvement in the Efficiency and Safety of the vehicle. These include a tachometer, seat-belt anchor that can be adjusted, and power window which makes it an automobile of high standards in the Chevrolet brand. Thus, the Brake Booster is a significant factor in enhancing the characteristics of the car's braking system, which is why every owner of Chevrolet Aveo should be familiar with its functions. In conclusion, this Chevrolet Aveo Brake Booster is one example how this brand continuously strive to be good and great not only in terms of design but more importantly in terms of functionality and safety that car owners need to have on their vehicle's.

Chevrolet Aveo Brake Booster Parts and Q&A

Brake Booster
96534598
Q: How to replace the vacuum brake booster on Chevrolet Aveo?
A:
The first step to replace the vacuum Brake Booster includes unplugging its electrical connector from the reservoir. For manual car owners we disconnect the Clutch Hose clip from the master cylinder before plugging the Clutch Hose and master cylinder outlets. Detach the master cylinder nuts then move the master cylinder forward while protecting the Brake Lines and get rid of the older booster housing seal. Unfasten the vac outlet clip from the booster then remove the brake lamp switch and brake pedal spring. Unfasten the clip and Pushrod attachment point on the pedal bracket. After taking off the support bracket-to-dash panel nuts remove the booster with the bracket assembly from dash panel position. Take off the booster bracket nuts then pull out the rubber boot and retainer which must be followed by removal of the Pushrod and adjustment sleeve before getting to the hex nut. Check the Pushrod and adjustment sleeve components for damage and suitable alignment before installing them onto the booster along with the hex nut. Tighten the assembly to 16 nm (12 ft. Lbs.). Insert the Pushrod into the adjustment sleeve before mounting the retainer with care to reach a 10-inch distance between the booster and fork bin center. Fit the rubber boot on the booster then fasten the brackets before tightening booster-to-support nuts to 12 nm (9 ft. Lbs.). Secure the dash panel parts with two 24 nm (18 ft. Lbs.) torque settings on the booster and support bracket nuts. Attach the master cylinder to the booster unit by installing a new booster housing seal then tighten all master cylinder connecting nuts to 24 nm (18 ft. Lbs.). Attach the new vacuum hose to booster with proper dohc engine connection and tighten new hose clamps. Place the Pushrod pin into its original position on the brake pedal bracket before reconnecting its spring and clip. Besides, attach and tighten the brake lamp switch.